Additive manufacturing using polyurea materials

ABSTRACT

Methods of additive manufacture using coreactive components are disclosed. Thermosetting compositions for additive manufacturing are also disclosed.

This invention was made with government support under Contract NumberDE-AC05-00OR22725 awarded by the U.S. Department of Energy and underCooperative Research and Development Agreement NFE-14-05242. Thegovernment has certain rights in the invention.

FIELD

The present invention relates to compositions and methods for additivemanufacturing of coreactive materials including polyureas.

BACKGROUND

Additive manufacturing is an area of significant interest. Many additivemanufacturing methods using a wide variety of materials have beendeveloped, each having their own advantages and disadvantages.

In PCT International Publication No. WO 2016/085914 additivemanufacturing using coreactive components is disclosed. The rheologicalparameters of coreactive compositions were determined and correlatedwith manufacturability.

SUMMARY

According to the present invention, methods of reactive additivemanufacturing comprise providing a first component comprising a firstprepolymer into a first pump; providing a second component comprising asecond prepolymer into a second pump, wherein the second prepolymer isreactive with the first prepolymer; pumping the first component from thefirst pump, and the second component from the second pump through amixer to provide a reactive compositions; and depositing the reactivecomposition through a nozzle connected to the mixer.

According to the present invention, reactive additive manufacturingcompositions comprise: a first component comprising a polyisocyanateprepolymer and a first viscosity; and a second component comprising apolyamine prepolymer and a second viscosity, wherein the first viscosityis within ±20% of the second viscosity, wherein viscosity is measuredusing an Anton Paar MCR 301 or 302 rheometer with a 25 mm-diameterparallel plate spindle, an oscillation frequency of 1 Hz and amplitudeof 0.3%, and with a rheometer plate temperature of 25° C.

According to the present invention, objects are formed usingcompositions according to the present invention.

According to the present invention, methods of additive manufacturing,comprise extruding the composition according to the present inventionusing a two component progressive cavity pump.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings described herein are for illustration purposes only. Thedrawings are not intended to limit the scope of the present disclosure.

FIG. 1 is a graph showing the complex viscosity during cure for twopolyurea compositions.

FIG. 2 is a graph showing the phase angle viscosity during cure for twopolyurea compositions.

FIG. 3 shows the shear storage modulus G′ and the shear loss modulus G″during cure for two polyurea compositions.

FIG. 4 is a graph showing the complex viscosity during cure for fourpolyurea compositions.

FIG. 5 is a graph showing the complex viscosity during cure for fourpolyurea compositions.

FIG. 6 is a graph showing the dependence of the viscosity η (cP) on theshear rate γ (sec⁻¹) for three (3) prepolymers.

DETAILED DESCRIPTION

For purposes of the following detailed description, it is to beunderstood that the invention may assume various alternative variationsand step sequences, except where expressly specified to the contrary.Moreover, other than in any operating examples or where otherwiseindicated, all numbers expressing, for example, quantities ofingredients used in the specification and claims are to be understood asbeing modified in all instances by the term “about.” Accordingly, unlessindicated to the contrary, the numerical parameters set forth in thefollowing specification and attached claims are approximations that mayvary depending upon the desired properties to be obtained by the presentinvention. At the very least, and not as an attempt to limit theapplication of the doctrine of equivalents to the scope of the claims,each numerical parameter should at least be construed in light of thenumber of reported significant digits and by applying ordinary roundingtechniques. Notwithstanding that the numerical ranges and parameterssetting forth the broad scope of the invention are approximations, thenumerical values set forth in the specific examples are reported asprecisely as possible. Any numerical value, however, inherently containscertain errors necessarily resulting from the standard variation foundin their respective testing measurements.

Also, it should be understood that any numerical range recited herein isintended to include all sub-ranges subsumed therein. For example, arange of “1 to 10” is intended to include all sub-ranges between (andincluding) the recited minimum value of 1 and the recited maximum valueof 10, that is, having a minimum value equal to or greater than 1 and amaximum value of equal to or less than 10.

The use of the singular includes the plural and plural encompassessingular, unless specifically stated otherwise. In addition, the use of“or” means “and/or” unless specifically stated otherwise, even though“and/or” may be explicitly used in certain instances.

Additive manufacturing using coreactive components has severaladvantages compared to alternative additive manufacturing methods.Additive manufacturing using coreactive components can create strongerparts because the materials forming successive layers can be coreactedto from covalent bonds between the layers. Also, because the componentshave a low viscosity when mixed higher filler content can be used. Thehigher filler content can be used to modify the mechanical and/orelectrical properties of the materials and the built object. Coreactivecomponents can extend the chemistries used in additively manufacturedparts to provide improved properties such as solvent resistance andthermal resistance.

For additive manufacturing of coreactive components it is generallydesirable that the rate of reaction between the reactive componentsand/or the deposition process be controlled such that the compositionmaintains a relatively low viscosity during deposition and increasesviscosity to provide a stable base upon which to apply subsequentlayers.

There are a number of chemistries that can be employed in additivemanufacturing of coreactive components. Examples of coreactive systemsinclude polyisocyanates and polyamines which form polyureas. Polyureasare attractive for use in reactive additive manufacturing. The reactionof polyisocyanates and polyamines can proceed rapidly at roomtemperature thereby avoiding the need to control heat flow duringdeposition. The polyurea reaction can also proceed rapidly in theabsence of a catalyst.

The present disclosure is directed to the production of structuralobjects using three-dimensional printing. A three-dimensional object maybe produced by forming successive portions or layers of an object bydepositing at least two coreactive components onto a substrate andthereafter depositing additional portions or layers of the object overthe underlying deposited portion or layer. Layers are successivelydeposited to build a printed object. The coreactive components can bemixed and then deposited or can be deposited separately. When depositedseparately, the components can be deposited simultaneously,sequentially, or both simultaneously and sequentially.

Deposition and similar terms refer to the application of a printingmaterial comprising a thermosetting or coreactive composition and/or itsreactive components onto a substrate (for a first portion of the object)or onto previously deposited portions or layers of the object. Eachcoreactive component may include monomers, prepolymers, adducts,polymers, and/or crosslinking agents, which can chemically react withthe constituents of the other coreactive component.

By “portions of an object” is meant subunits of an object, such aslayers of an object. The layers may be on successive horizontal parallelplanes. The portions may be parallel planes of the deposited material orbeads of the deposited material produced as discreet droplets or as acontinuous stream of material. The at least two coreactive componentsmay each be provided neat or may also include a solvent (organic and/orwater) and/or other additives as described below. Coreactive componentsprovided by the present disclosure may be substantially free of solvent.By substantially free is meant less than about 5 wt %, less than about 4wt %, less than about 2 wt %, or less than 1 wt % of solvent, where wt %is based on the total weight of a composition.

The at least two coreactive components may be mixed together andsubsequently deposited as a mixture of coreactive components that reactto form portions of an object. For example, two coreactive componentsmay be mixed together and deposited as a mixture of coreactivecomponents that react to form a thermoset by delivery of at least twoseparate streams of the coreactive components into a mixer such as astatic mixer and/or a dynamic mixer to produce a single stream that isthen deposited. The coreactive components may be at least partiallyreacted by the time a composition comprising the reaction mixture isdeposited. The deposited reaction mixture may react at least in partafter deposition and may also react with previously deposited portionsand/or subsequently deposited portions of the object such as underlyinglayers or overlying layers of the object.

The two or more coreactive components can be deposited by dispensingmaterials through a disposable nozzle attached to a progressive cavitytwo-component dosing system such as a ViscoTec ecoDUO 450 precisiondosing system, where the coreactive components are mixed in-line. Atwo-component dosing system can comprise, for example, two progressivecavity pumps that separately dose reactants into a disposable staticmixer dispenser or into a dynamic mixer. Other suitable pumps includesyringe pumps and peristaltic pumps. Upon dispensing, the coreactivematerials form an extrudate to provide an initial layer of coreactivematerial and successive layers on a base. The dosing system can bepositioned orthogonal to the base, but also may be set at any suitableangle to form the extrudate such that the extrudate and dosing systemform an obtuse angle with the extrudate being parallel to the base. Theextrudate refers to the combined coreactive components that have beenmixed, for example, in a static mixer or in a dynamic mixer.

The base, the dosing system, or both the base and the dosing system maybe moved to build up a three-dimensional object. The motion can be madein a predetermined manner, which may be accomplished using any suitableCAD/CAM method and apparatus such as robotics and/or computerize machinetool interfaces.

An extrudate may be dispensed continuously or intermittently to form aninitial layer and successive layers. For intermittent dispensing, adosing system may interface with a relay switch to shut off the pumps,such as the progressive cavity pumps and stop the flow of coreactivematerials. Any suitable switch such as an electromechanical switch thatcan be conveniently controlled by any suitable CAD/CAM methodology canbe used.

A dispensing system can include an in-line static and/or dynamic mixeras well as separate pressurized pumping compartments to hold the atleast two coreactive components and feed the coreactive materials intothe static and/or dynamic mixer. A mixer such as an active mixer cancomprise a variable speed central impeller having high shear bladeswithin a conical nozzle. A range of conical nozzles may be used whichhave an exit orifice diameter from 0.2 mm to 4.0 mm.

A range of static and/or dynamic mixing nozzles may be used which have,for example, an exit orifice diameter from 0.6 mm to 2.5 mm, and alength from 30 mm to 150 mm. For example, an exit orifice diameter canbe from 0.2 mm to 4.0 mm, from 0.4 mm to 3.0 mm, from 0.6 mm to 2.5 mm,from 0.8 mm to 2 mm, or from 1.0 mm to 1.6 mm. A static mixer and/ordynamic can have a length, for example, from 10 mm to 200 mm, from 20 mmto 175 mm, from 30 mm to 150 mm, or from 50 mm to 100 mm. A mixingnozzle can include a static and/or dynamic mixing section and adispensing section coupled to the static and/or dynamic mixing section.The static and/or dynamic mixing section can be configured to combineand mix the coreactive materials. The dispensing section can be, forexample, a straight tube having any of the above orifice diameters. Thelength of the dispensing section can be configured to provide a regionin which the coreactive components can begin to react and buildviscosity before being deposited on the object. The length of thedispensing section can be selected, for example, based on the speed ofdeposition, the rate of reaction of the coreactants, and the desiredviscosity. Coreactants can have a residence time in the static and/ordynamic mixing nozzle, for example, from 0.25 seconds to 5 seconds, from0.3 seconds to 4 seconds, from 0.5 seconds to 3 seconds, or from 1seconds to 3 seconds. Other residence times can be used as appropriatebased on the curing chemistries and curing rates. The flow rate can be,for example, from 1 mL/min to 20 mL/min, from 2 mL/min to 15 mL/min,from 3 mL/min to 10 mL/min, or from 4 mL/min to 8 mL/min, through anozzle having a diameter, for example, from 0.8 mm to 1 mm.

A static and/or dynamic mixing nozzle can be heated or cooled to controlthe rate of reaction between the coreactive materials and/or theviscosity of the coreactive materials.

For example, coreactive compositions useful in additive manufacturingcan exhibit a tack free time measured using a cotton ball test asdescribed in the examples of longer than 3 minutes, longer than 4minutes, longer than 5 minutes, or longer than 6 minutes after mixingthe coreactive compositions. Coreactive compositions having a tack freetime less than 3 minutes tend to cure too fast for practicalapplication. For example, such coreactive compositions can become tooviscous in the static and/or dynamic mixing nozzle and can clog thenozzle.

Coreactive compositions useful in additive manufacturing can have aG″/G′ ratio (ratio of shear loss modulus G″ to shear storage modulusG′), for example, greater than 2, greater than 3 or greater than 4,determined at t=0 after mixing the coreactive compositions.

Suitable coreactive chemistries include polyurea chemistries. As anexample of a polyurea chemistry, a polyisocyanate can comprise apolyisocyanate prepolymer and/or polyisocyanate monomer, and a polyaminecomponent can comprise a polyamine prepolymer and/or polyamine monomer.

A polyisocyanate and/or a polyamine can be difunctional, trifunctional,or a combination thereof. A polyisocyanate and/or polyamine can compriseprepolymers and/or monomers having a functionality, for example fromfour (4) to six (6).

A polyisocyanate prepolymer and/or polyamine prepolymer can have amolecular weight, for example, from 500 Daltons to 8,000 Daltons, from1,000 Daltons to 6,000 Daltons, from 1,500 Daltons to 5,500 Daltons, orfrom 2,000 Daltons to 6,000 Daltons.

A polyisocyanate can comprise the reaction product of reactantscomprising a polyol prepolymer and a polyisocyanate such as adiisocyanate and/or the reaction product of reactants comprising apolyamine prepolymer and a polyisocyanate such as a diisocyanate.

A polyisocyanate can be prepared by reacting a polytetramethylene etherglycol such as Polymeg® (LyondellBasell) having a molecular weightwithin a range from 500 Daltons to 2,500 Daltons with a diisocyanatesuch as isophorone diisocyanate.

A polyisocyanate can be prepared by reacting a polyetheramine such asJeffamine® (Huntsman), e.g., a polyoxypropylenediamine, having amolecular weight within a range from 500 Daltons to 2,500 Daltons with adiisocyanate such as isophorone diisocyanate.

Reactive compositions provided by the present disclosure can comprise afiller. For example a reactive composition can comprise from 0.1 wt % to30 wt %, from 0.1 wt % to 20 wt %, from 2 wt % to 20 wt %, or from 5 wt% to 15 wt %, wherein wt % is based on the total weight of the reactivecomposition. The polyisocyanate component, the polyamine component, orboth the polyisocyanate and polyamine components can comprise filler.

To facilitate complete mixing of the coreactants in the static and/ordynamic mixing nozzle, it can be useful that the viscosity of thecoreactive compositions be similar such as, for example, within 5%,within 10%, or within 20% of each other. The filler can be added toimpart certain properties to a built object and/or as rheology modifier.

When using a coreactive system in which one component comprises a highermolecular weight prepolymer and the second component comprises a lowermolecular weight curing agent, it can be desirable to increase theviscosity of the second component comprising the lower molecular weightcuring agent. Increasing the amount (wt %) filler in the reactivecomposition can increase the initial viscosity of a component and canslow the increase in viscosity of the curing composition.

The complex viscosity |η*| and the phase angle δ for two compositionsafter mixing with the polyamine curing agent are shown in FIGS. 1 and 2,respectively. Note that the compositions referred to in the figures asComposition A and Composition B do not correspond to the compositionsevaluated in Example 1.

Composition B (with Jeffamine® D-2000/IPDI) is more elastic thancomposition A (with Polymeg® 2000/IPDI). A complex viscosity |η*| withina range from about 10⁴ to 10⁵ Pa·s is suitable for additivemanufacturing and provides successful builds. However, as reflected inthe low initial phase angle of about 45° (FIG. 2), composition B rapidlycures rendering the material unsuitable for additive manufacturing.Composition A, on the other hand begins with an initial phase angle δ ofabout 65° and does not fall to 45° until about 8 minutes after thepolyisocyanate and polyamine components are first mixed. In general, acomposition is no longer printable when the phase angle is 45° and less.

FIG. 3 shows the shear storage modulus G′ and the shear loss modulus G″with time for two compositions. Composition A comprising Polymeg®2000/IPDI, Jeffamine® T-5000, and 5 wt % filler exhibited an initialmodulus ratio G″/G′ of about 2 and after about 7 minutes reached a ratioof about 1.

In comparison, reactive composition B comprising Jeffamine® D-2000/IPDIJeffamine® T-5000, and 5 wt % filler exhibited an initial modulus ratioG″/G′ of about 1 and increased over time to a ratio less than 1.

Phase angle δ depicted in FIG. 2 is calculated from the values reportedin FIG. 3 using the relation tan δ=G″/G′.

FIGS. 4 and 5 shown the complex viscosity and phase angle, respectivelyfor various compositions having different amounts of filler. CompositionA included Polymeg® 2000/IPDI combined with Jeffamine® T5000, Clearlink®1000, Petrolite® T5000, and filler. Composition B included Jeffamine®D2000/IPDI combined with Jeffamine® T5000, Clearlink® 1000, Petrolite®T5000, and filler. The amount of the Cabosil® TS-720 fumed silica isindicated in the figures.

Also, the initial storage modulus G′ and shear loss modulus G″ was aboutone (1) order of magnitude less for the Polymeg® 2000 compositioncompared to the Jeffamine® D-2000 composition.

Based on the experimental results, it has been determined thatcompositions having the following properties after mixing the coreactivecomponents, either independently or in various combinations can besuccessfully printed using, for example, a two component progressivecavity pump: initial G″/G′ ratio is within a range from 1 to 5, such asgreater than 2, greater than 3 or greater than 4; initial phase angle δwithin a range from 45° to 89°; tan δ>45 at 7 minutes; and/or initialviscosities of the single coreactive components differ from each otherby no more than 20%.

FIG. 6 shows the shear dependent viscosity for six (6) prepolymers.Polymeg® 2000, IPDI-terminated Polymeg® 2000, and Jeffamine® T-5000 havesimilar viscosities at shear rates from 0.1 sec⁻¹ to about 2 sec⁻¹.

For polyurea curing chemistries in additive manufacturing it can beuseful for the a coreactive composition to have a viscosity within arange from 0.7×10⁴ cP to 0.1.3×10⁴ cP, from 0.8×10⁴ cP to 1.2×10⁴ cP, orfrom 0.9×10⁴ cP to 1.1×10⁴ cP, measured using an Anton Paar MCR 301 or302 rheometer with a gap set to 1 mm, with a 25 mm-diameter parallelplate spindle, and an oscillation frequency of 1 Hz and amplitude of0.3%.

The high viscosity and low gel time of the Jeffamine®-derivedprepolymer, Jeffamine® T-500 in FIG. 6, may can also be due to thepresence of pendent hydroxyl groups that can increase the hydrogenbonding between prepolymers.

Throughout an additively printed object, different parts of an objectmay be formed using different proportions of the two coreactivecomponents such that different parts of an object may be characterizedby different material properties. For example, some parts of an objectmay be rigid and other parts of an object may be flexible.

It will be appreciated that the viscosity, reaction rate, and otherproperties of the coreactive components may be adjusted to control theflow of the coreactive components and/or the thermosetting compositionssuch that the deposited portions and/or the object achieves and retainsa desired structural integrity following deposition. The viscosity ofthe coreactive components may be adjusted by the inclusion of a solvent,or the coreactive components may be substantially free of a solvent orcompletely free of a solvent. The viscosity of the coreactive componentsmay be adjusted by the inclusion of a filler, or the coreactivecomponents may be substantially free of a filler or completely free of afiller. The viscosity of the coreactive components may be adjusted byusing components having lower or higher molecular weight. For example, acoreactive component may comprise a prepolymer, a monomer, or acombination of a prepolymer and a monomer. The viscosity of thecoreactive components may be adjusted by changing the depositiontemperature. The coreactive components may have a viscosity andtemperature profile that may be adjusted for the particular depositionmethod used, such as mixing prior to deposition and/or ink-jetting. Theviscosity may be affected by the composition of the coreactivecomponents themselves and/or may be controlled by the inclusion ofrheology modifiers as described herein.

It can be desirable that the viscosity and/or the reaction rate be suchthat following deposition of the coreactive components the compositionretains an intended shape. For example, if the viscosity is too lowand/or the reaction rate is too slow a deposited composition may flow ina way the compromises the desired shape of a finished object. Similarly,if the viscosity is too high and/or the reaction rate is too fast, thedesired shape may be compromised.

For example, the coreactive components that are deposited together mayeach have a viscosity at 25° C. and a shear rate at 0.1 sec⁻¹ to 10²sec⁻¹ from 5,000 centipoise (cP) to 20,000 cP, from 6,000 cP to 15,000cP, from 7,000 cP to 13,000 cP, or from 8,000 cP to 12,000 cP. Viscosityvalues are measured using an Anton Paar MCR 301 or 302 rheometer with agap from 1 mm.

The rate of interlayer crosslinking between successive and adjacentlayers of a deposited object can be controlled to facilitate interlayerreaction and thereby improve the interlayer strength. The rate ofinterlayer crosslinking can be controlled, for example, by adjusting thetime between deposition of successive layers, adjusting the temperature,adjusting the concentration of a catalyst, and/or adjusting thecomponents of the composition such as the amount of monomer andprepolymer. A deposited layer may be homogeneous or a deposited layermay be inhomogeneous. For an inhomogeneous layer, a cross-section of thelayer may have different chemical compositions. For example to improveinterlayer adhesion, a part of a layer may have an excess of a certaincoreactive functionality that can then react with an excess of acoreactive functionality of an overlying layer. Similarly, to improveinterlayer adhesion, a lower part of a layer may have an excess of acertain coreactive functionality that can then react with an excess of acoreactive functionality of an underlying layer. To improve interlayeradhesion, a tie coating, film, or layer may be applied or deposited overa deposited layer prior to or during deposition of an overlying layer.

The coreactive components may include a first component having at leasttwo functional groups per molecule (referred to as the “A” functionalgroups) and a second component having at least two functional groups permolecule (referred to as the “B” functional groups), where the Afunctional groups and the B functional groups are coreactive with eachother, are different from each other, and at least one of the twocoreactive components includes a saturated functional group.

A “saturated functional group” refers to a functional group of componentcoreactive component that does not include an unsaturated reactivegroup, although there may be unsaturation in other (non-reactive)portions of the compound of the coreactive component. An example of asaturated group includes thiol groups and an example of an unsaturatedgroup includes alkenyl and acrylate groups. Examples of saturatedfunctional groups include thiol, hydroxyl, primary amine, secondaryamine, and epoxy groups. In certain compositions, a saturated functionalgroup can be a thiol, a primary amine, a secondary amine, or acombination of any of the foregoing. In certain compositions, asaturated functional group can be a thiol, a primary amine, a secondaryamine, an epoxy, or a combination of any of the foregoing. Examples ofunsaturated functional groups include alkenyl groups, activatedunsaturated groups such as acrylate, maleic, or fumaric acid groups,isocyanate groups, acyclic carbonate groups, acetoacetate groups,carboxylic acid groups, Michael acceptor groups, vinyl ether groups,(meth)acrylate groups, and malonate groups.

In certain compositions a saturated group comprises amine groups, and anunsaturated group comprise isocyanate groups.

Compositions provided by the present disclosure can comprise a firstcomponent comprising a first functional group, and a second componentcomprising a second functional group, wherein the second functionalgroup is reactive with the first functional group, and both of thefunctional groups do not comprise ethylenically unsaturated groups.Examples of ethylenically unsaturated groups include (meth)acrylategroups, Michael acceptor groups, and vinyl ether groups.

In certain compositions provided by the present disclosure the firstcomponent and the second component do not include a polyisocyanate and apolyol.

B functional groups may be capable of reacting with the A functionalgroups at moderate temperature such as less than 140° C., less than 100°C., less than 60° C., less than 50° C., less than 40° C., less than 30°C., or less than 25° C. The A and B functional groups may react togetherat room temperature such as 20° C. One or both of the coreactivecomponents may have on average more than two reactive groups permolecule, in which case the mixture of coreactive components comprises athermosetting composition. Suitable coreactive functional groups aredescribed, for example, in Noomen, Proceedings of the XIIIthInternational Conference in Organic Coatings Science and Technology,Athens, 1987, page 251; and in Tillet et al., Progress in PolymerScience, 36 (2011), 191-217, which is incorporated by reference in itsentirety. The reaction between the A groups and the B groups may notinvolve the elimination of a by-product. Such reactions are oftenreferred to as addition reactions. Examples of suitable coreactivefunctional groups A and B are listed in Table 1.

TABLE 1 Functional Groups. Functional Groups A Functional Groups BCarboxylic acid Epoxy Activated unsaturated groups such as Primary orsecondary amine acrylate, maleic or fumaric Isocyanate Primary orsecondary amine Isocyanate Hydroxyl Cyclic carbonate Primary orsecondary amine Acetoacetate Primary or secondary amine Epoxy Primary orsecondary amine Thiol Alkenyl Thiol Vinyl ether Thiol (Meth)acrylateActivated unsaturated groups such as Malonate acrylate or maleic

A first coreactive component may include compounds having more than onetype of functional group A, and the second coreactive component mayinclude components having more than one type of functional group B, suchthat an additive manufacturing material can comprise at least two setsof coreactive A and B groups, wherein at least one coreactive componenthas a functional group that is saturated. For example, a firstcoreactive component may have hydroxyl groups and secondary amine groups(i.e. at least two different functional groups) and the secondcoreactive component may have isocyanate groups. One or both of thecoreactive components may optionally comprise a catalyst for thereaction between the A groups and the B groups.

The A groups and the B groups may be attached to any suitable compoundsuch as a monomer and/or a prepolymer. Optionally, the A groups and theB groups may be attached to an oligomer, polymer, or prepolymer such aspolyester, polyurethane, or acrylic oligomer, polymer, or prepolymer. Ingeneral, monomers refer to compounds without repeating units in thebackbone, and can be characterized, for example, by a molecular weightless than 600 Daltons, less than 500 Daltons, or less than 400 Daltons.In general, a prepolymer refers to a compound having repeat units inbackbone and can be characterized, for example, by a molecular weightfrom 1,000 Daltons to 20,000 Daltons, from 1,000 Daltons to 10,000Daltons, or from 2,000 Daltons to 5,000 Daltons.

The functional groups A and B may be terminal groups and/or pendentgroups. A coreactive component can have a functionality of two or afunctionality greater than two, such as a functionality from 2 to 6.Each functional group of a coreactive component can be the same orcertain functional groups of a coreactive component can be different.For example, a coreactive component can have more than one differenttype of functional group reactive with an isocyanate, such as a primaryamine group, a secondary amine group, or a hydroxyl group.

In a composition comprising at least two coreactive components, thefirst component can comprise a polyamine and the second component cancomprise a polyisocyanate; the first component can comprise apolyalkenyl compound and the second component can comprise a polythiol;the first component can comprise a Michael addition acceptor and thesecond component can comprise a Michael addition donor; or a combinationof any of the foregoing; In a composition comprising at least twocoreactive components, the first component can comprise anisocyanate-functional prepolymer; and the second functional group cancomprise a primary amine, a secondary amine, a hydroxyl, or acombination of any of the foregoing.

A composition for additive manufacturing can comprise a first componentcomprising a first functional group, and a second component comprising asecond functional group, wherein the first and second functional groupsare reactive with each other, and at least one of the first functionalgroup and the second functional group comprise a saturated functionalgroup. One of the first and second functional groups may be anunsaturated functional group, or both the first and second functionalgroups may be a saturated functional group. Both the first functionalgroup and the second functional groups are not unsaturated functionalgroups. A composition provided by the present disclosure may containadditional coreactive components, which may comprise saturated and/orunsaturated functional groups.

The coreactive functional groups can react to form covalent bonds. Thereaction between the coreactive functional groups can be catalyzed by acatalyst. In certain compositions, the reaction between the coreactivefunctional groups does not involve a free-radical initiated reaction.Compositions provided by the present disclosure may be thermosetcompositions.

Compositions provided by the present disclosure may include twocoreactive components or more than two coreactive components. A reactivecomponent can comprise a combination of reactive components having thesame functional group, such as a combination of monomers and prepolymershaving the same functional group. An additional coreactive component cancomprise a compound having a different functional group reactive with afirst functional group or the second functional group. An additionalcoreactive component can impart an additional property to thecomposition. For example, the reaction rate of the additional coreactivecomponent with one of the other coreactive components may be rapid andthereby facilitate the ability of a deposited layer to maintain adesired shape before the other components fully cure.

The first component and the second component can be combined in asuitable ratio to form a curable composition. For example, thefunctional Group A to functional Group B equivalent ratio of a curablecomposition can be from 1:1 to 1.5:1, from 1:1 to 1.45:1, from 1:1 to3:1, from 1.2:1 to 1.5:1, or from 1.2:1 to 1.4:1. A suitable functionalGroup A to functional Group B equivalent ratio of a curable compositioncan be, for example, from 2:1 to 1:2, from 1.5:1 to 1:1.5, or from 1.1:1to 1:1.1.

Compositions provided by the present disclosure can include one or bothof the coreactive components such that the ratio of coreactivecomponents in one portion of the object differs from the ratio ofcoreactive components in another part of the object. In this manner,portions of an object may have differing final compositions. Thedifferent compositions may differ by the weight percent of thecoreactive compositions, the equivalent ratio of reactive monomers orreactants within the coreactive compositions, the type and/or level offiller, the crosslinking density, and/or properties such as glasstransition temperature. Accordingly, one portion of an object producedin the three-dimensional printing may have different material propertiessuch as different chemical, physical, thermal, or material propertiesthan those of another portion of the three-dimensional object.

In addition, one portion of an object may partially react with at leastsome other coreactive components in an adjacent portion of the object.Such reaction may occur during deposition and/or after the coreactivecomponents are deposited in each adjacent portion, whereby thecoreactive components react in part within each adjacent portion and thecoreactive components between adjacent portions react. In this manner,the deposited portions of an object may be covalently bound together asthe coreactive compositions react between the portions of the object,thereby increasing the physical and structural integrity of thethree-dimensional object. For example, unreacted isocyanate and/or aminegroups present on the surface of an underlying deposited layer, canreact with unreacted groups of a subsequently deposited layer. Thisincreases the strength/integrity of the object by providing reactionbetween layers of deposited material, in addition to reaction within thesame layer.

An additively manufactured object can include layers formed from athermosetting or coreactive composition, such as a polyurea composition,that is produced from at least two deposited coreactive components andwhich may be crosslinked. In the case of polyurea, one of the coreactivecomponents may include an isocyanate-functional prepolymer or oligomerand another coreactive component may include an amine such as a primaryor secondary amine. The isocyanate-functional coreactive components mayfurther include isocyanate-functional monomers. The amine containingcoreactive component may further include another reactant withfunctional groups reactive with the isocyanate-functional prepolymer,oligomer, and/or monomer such as hydroxyl groups. Adjacent portions of aprinted three-dimensional object may be reacted with some of thecoreactive compositions in one or more adjacent portions.

For a polyurea composition, the coreactive components may include anisocyanate-functional component that may include polyisocyanatemonomers, prepolymers, oligomers, adducts, polymers, or a blend ofpolyisocyanates. A polyisocyanate prepolymer can be a polyisocyanatewhich is pre-reacted with a sufficient amount of polyamine(s) or otherisocyanate-reactive components such as one or more polyols, so thatreactive isocyanate sites on the polyisocyanate remain in theisocyanate-functional prepolymer.

A polyisocyanate can include a polyisocyanate prepolymer prepared byreacting a prepolymer having terminal groups reactive with isocyanategroups with a polyisocyanate such as a diisocyanate. For example, apolyisocyanate prepolymer can be prepared by reacting a polyolprepolymer and/or a polyamine prepolymer with a polyisocyanate such as adiisocyanate.

Suitable monomeric polyisocyanates include, for example, isophoronediisocyanate (IPDI), which is3,3,5-trimethyl-5-isocyanato-methyl-cyclohexyl isocyanate; hydrogenateddiisocyanates such as cyclohexylene diisocyanate,4,4′-methylenedicyclohexyl diisocyanate (H₁₂MDI); mixed aralkyldiisocyanates such as tetramethylxylyl diisocyanates,OCN—C(—CH₃)₂—C₆H₄C(CH₃)₂—NCO; and polymethylene isocyanates such as1,4-tetramethylene diisocyanate, 1,5-pentamethylene diisocyanate,1,6-hexamethylene diisocyanate (HMDI), 1,7-heptamethylene diisocyanate,2,2,4- and 2,4,4-trimethylhexamethylene diisocyanate, 1,10-decamethylenediisocyanate and 2-methyl-1,5-pentamethylene diisocyanate.

Aliphatic isocyanates can be useful in producing three-dimensionalpolyurea objects that are resistant to degradation by UV light. However,in other circumstances, less costly aromatic polyisocyanates may be usedwhen durability is not of significant concern. Examples of monomericaromatic polyisocyanates include phenylene diisocyanate, toluenediisocyanate (TDI), xylene diisocyanate, 1,5-naphthalene diisocyanate,chlorophenylene 2,4-diisocyanate, bitoluene diisocyanate, dianisidinediisocyanate, tolidine diisocyanate and alkylated benzene diisocyanatesgenerally; methylene-interrupted aromatic diisocyanates such asmethylenediphenyl diisocyanate, especially the 4,4′-isomer (MDI)including alkylated analogs such as 3,3′-dimethyl-4,4′-diphenylmethanediisocyanate and polymeric methylenediphenyl diisocyanate.

Suitable polyisocyanates also include polyisocyanates prepared fromdimers and trimers of diisocyanate monomers. Dimers and trimers ofdiisocyanate monomers can be prepared, for example, by methods describedin U.S. Pat. No. 5,777,061 at column 3, line 44 through column 4, line40, which is incorporated by reference in its entirety. Dimers andtrimers of diisocyanate monomers may contain linkages selected fromisocyanurate, uretdione, biuret, allophanate and combinations thereof,such as Desmodur® N3600, Desmodur® CP2410, and Desmodur® N3400,available from Bayer Material Science.

A polyisocyanate can also comprise a polyisocyanate prepolymer. Forexample, a polyisocyanate can include an isocyanate-terminated polyetherdiol, an isocyanate-terminated extended polyether diol, or a combinationthereof. An extended polyether diol refers to a polyether diol that hasbeen reacted with an excess of a diisocyanate resulting in anisocyanate-terminated polyether prepolymer with increased molecularweight and urethane linkages in the backbone. Examples of polyetherdiols include Terathane® polyether diols such as Terathane® 200 andTerathane® 650 available from Invista or the PolyTHF® polyether diolsavailable from BASF. Isocyanate-terminated polyether prepolymers can beprepared by reacting a diisocyanate and a polyether diol as described inU.S. Application Publication No. 2013/0244340, which is incorporated byreference in its entirety. The number average molecular weight of anextended isocyanate-terminated prepolymer can be, for example, from 250Daltons to 10,000 Daltons, or from 500 Daltons to 7,500 Daltons.

A polyisocyanate prepolymer can include an isocyanate-terminatedpolytetramethylene ether glycol such as polytetramethylene ether glycolsproduced through the polymerization of tetrahydrofuran. Examples ofsuitable polytetramethylene ether glycols include Polymeg® polyols(LyondellBasell), PolyTHF® polyether diols (BASF), or Terathane® polyols(Invista).

A polyisocyanate prepolymer can include an isocyanate-terminatedpolyetheramine. Examples of polyether amines include Jeffamine®polyetheramines (Huntsman Corp.), and polyetheramines available fromBASF. Examples of suitable polyetheramines includepolyoxypropylenediamine.

A polyisocyanate prepolymer can include a difunctional isocyanate, atrifunctional isocyanate, a difunctional isocyanate-terminatedprepolymer, an extended difunctional isocyanate-terminated prepolymer,or a combination of any of the foregoing.

The amine-functional coreactive component used to produce athree-dimensional polyurea object may include primary and/or secondaryamines or mixtures thereof. The amines may be monoamines, or polyaminessuch as diamines, triamines, higher polyamines and/or mixtures thereof.The amines also may be aromatic or aliphatic such as cycloaliphatics.Examples of suitable aliphatic polyamines include, ethylene diamine,1,2-diaminopropane, 1,4-diaminobutane, 1,3-diaminopentane,1,6-diaminohexane, 2-methyl-1,5-pentane diamine,2,5-diamino-2,5-dimethylhexane, 2,2,4- and/or2,4,4-trimethyl-1,6-diamino-hexane, 1,11-diaminoundecane,1,12-diaminododecane, 1,3- and/or 1,4-cyclohexane diamine,1-amino-3,3,5-trimethyl-5-aminomethyl-cyclohexane, 2,4- and/or2,6-hexahydrotolulene diamine, 2,4′- and/or 4,4′-di amino-dicyclohexylmethane, 5-amino-1,3,3-trimethylcyclohexanemethylamine(isophoronediamine), 1,3-cyclohexanebis(methylamine) (1,3 BAC), and3,3′-dialkyl-4,4′-diaminodicyclohexyl methanes (such as3,3′-dimethyl-4,4′-diaminodicyclohexyl methane and3,3′-diethyl-4,4′-diaminodicyclohexyl methane), 2,4- and/or2,6-diaminotoluene and 2,4′- and/or 4,4′-diaminodiphenyl methane, ormixtures thereof.

Suitable secondary amines include acrylates and methacrylate-modifiedamines. By “acrylate and methacrylate modified amines” includes bothmono- and poly-acrylate modified amines as well as acrylate ormethacrylate modified mono- or poly-amines. Acrylate or methacrylatemodified amines can include aliphatic amines.

A secondary amine may include an aliphatic amine, such as acycloaliphatic diamine. Such amines are available commercially fromHuntsman Corporation (Houston, Tex.) under the designation of Jefflink™such as Jefflink™ 754. The amine may be provided as an amine-functionalresin. Such amine-functional resins may be a relatively low viscosity,amine-functional resins suitable for use in the formulation of highsolids polyurea three-dimensional objects. An amine-functional resin maycomprise an ester of an organic acid, for example, an asparticester-based amine-functional reactive resin that is compatible withisocyanates; e.g., one that is solvent-free. An example of suchpolyaspartic esters is the derivative of diethyl maleate and1,5-diamino-2-methylpentane, available commercially from BayerCorporation. PA under the trade name Desmophen™ NH1220. Other suitablecompounds containing aspartate groups may be employed as well.

An amine-functional coreactive component also may include high molecularweight primary amines, such as polyoxyalkyleneamines.Polyoxyalkyleneamines contain two or more primary amino groups attachedto a backbone, derived, for example, from propylene oxide, ethyleneoxide, or a mixture thereof. Examples of such amines includepolyoxypropylenediamine and glycerol tris[poly(propylene glycol),amine-terminated] ether such as those available under the designationJeffamine™ from Huntsman Corporation. Such polyetheramines can have amolecular weight from 200 Daltons to 7,500 Daltons, such as, forexample, Jeffamine™ D-230, D-400, D-2000, T-403 and T-5000.

An amine-functional coreactive component may also include an aliphaticsecondary amine such as Clearlink® 1000, available from Dor-KetalChemicals, LLC.

An amine-functional coreactive component can comprise anamine-functional aspartic acid ester, a polyoxyalkylene primary amine,an aliphatic secondary amine, or a combination of any of the foregoing.

For a polyurea formed from coreactive components comprising anisocyanate and a (meth)acrylate amine reaction product of a monoamineand poly(meth)acrylate, the term “(meth)acrylate” denotes both theacrylate and the corresponding (meth)acrylate. The poly(meth)acrylatemay be any suitable poly(meth)acrylate and mixtures thereof. Apoly(meth)acrylate can include a di(meth)acrylate, a poly(meth)acrylatecan comprise tri(meth)acrylate, or a poly(meth) acrylate can includetetra(meth)acrylate. Suitable di(meth)acrylates include, for example,ethylene glycol, di(meth)acrylate, 1,3-butylene glycol di(meth)acrylate,1,4-butanediol di(meth)acrylate, 2,3-dimethylpropane1,3-di(meth)acrylate, 1,6-hexanediol di(meth)acrylate, propylene glycoldi(meth)acrylate, dipropylene glycol di(meth)acrylate, tripropyleneglycol di(meth)acrylate, tetraethylene glycol di(meth)acrylate,tetrapropylene glycol di(meth)acrylate, ethoxylated hexanedioldi(meth)acrylate, propoxylated hexanediol di(meth)acrylate, neopentylglycol di(meth)acrylate, alkoxylated neopentyl glycol di(meth)acrylate,hexylene glycol di(meth)acrylate, diethylene glycol di(meth)acrylate,polyethylene glycol di(meth)acrylate, polybutadiene di(meth)acrylate,thiodiethyleneglycol di(meth)acrylate, trimethylene glycoldi(meth)acrylate, triethylene glycol di(meth)acrylate, alkoxylatedhexanediol di(meth)acrylate, alkoxyolated neopentyl glycoldi(meth)acrylate, pentanediol di(meth)acrylate, cyclohexane dimethanoldi(meth)acrylate, ethoxylated bis-phenol A di(meth)acrylate, andcombinations of any of the foregoing. Examples of tri and higher(meth)acrylates include glycerol tri(meth)acrylate, trimethylolpropanetri(meth)acrylate, ethoxylated trimethylolpropane tri(meth)acrylate,propoxylated trimethylolpropane tri(meth)acrylate, ditrimethylolpropanetetra(meth)acrylate, pentaerythritol tetra(meth)acrylate, ethoxylatedpentaerythritol tetra(meth)acrylate, propoxylated pentaerythritoltetra(meth)acrylate, and dipentaerythritol penta(meth)acrylate. Othersuitable poly(meth)acrylate oligomers include (meth)acrylate ofepoxidized soya oil and urethane acrylates of polyisocyanates andhydroxyalkyl (meth)acrylates. Mixtures of poly(meth)acrylate monomersmay also be used, including mixtures of mono, di, tri, and/or tetra(meth)acrylate.

Other suitable poly(meth)acrylates include urethane (meth)acrylates suchas those formed from the reaction of hydroxyl-functional (meth)acrylatewith a polyisocyanate or with an isocyanate-functional adduct of apolyisocyanate and a polyol or a polyamine. Suitable hydroxyl-functional(meth)acrylates include 2-hydroxyethyl, 1-methyl-2-hydroxyethyl,2-hydroxypropyl, 2-hydroxybutyl, 4-hydroxybutyl, and the like. Suitablepolyisocyanates include, for example, any of the monomeric or oligomericisocyanates, or isocyanate prepolymers disclosed herein.

A thermosetting or coreactive composition provided by the presentdisclosure can be based on thiol-ene chemistry. For example, athermosetting composition provided by the present invention havingthiol-ene functionality may include a polyene coreactive componentcomprising compounds or prepolymers having terminal and/or pendentolefinic double bonds, such as terminal alkenyl groups. Examples of suchcompounds include (meth)acrylic-functional (meth)acrylic copolymers,epoxy acrylates such as epoxy resin (meth)acrylates (such as thereaction product of bisphenol A diglycidyl ether and acrylic acid),polyester (meth)acrylates, polyether (meth)acrylates, polyurethane(meth)acrylates, amino (meth)acrylates, silicone (meth)acrylates, andmelamine (meth)acrylates.

Examples of suitable polyurethane (meth)acrylates include reactionproducts of polyisocyanates such as 1,6-hexamethylene diisocyanateand/or isophorone diisocyanate including isocyanurate and biuretderivatives thereof with hydroxyalkyl (meth)acrylates such ashydroxyethyl (meth)acrylate and/or hydroxypropyl (meth)acrylate.Examples of suitable polyester (meth)acrylates are the reaction productsof (meth)acrylic acid or anhydride with polyols, such as diols, triolsand tetraols, including alkylated polyols, such as propoxylated diolsand triols. Examples of suitable polyols include 1,4-butane diol,1,6-hexane diol, neopentyl glycol, trimethylol propane, pentaerythritoland propoxylated 1,6-hexane diol. Examples of suitable polyester(meth)acrylates include glycerol tri(meth)acrylate, trimethylolpropanetri(meth)acrylate, pentaerythritol tri(meth)acrylate, andpentaerythritol tetra(meth)acrylate. Mixtures of polyurethane(meth)acrylates and polyester (meth)acrylates may be used.

In addition to (meth)acrylates, (meth)allyl compounds or prepolymers maybe used either alone or in combination with (meth)acrylates. Examples of(meth)allyl compounds include polyallyl ethers such as the diallyl etherof 1,4-butane diol and the allyl ether of trimethylol propane. Examplesof other (meth)allyl compounds include polyurethanes containing(meth)allyl groups. For example, reaction products of polyisocyanatessuch as 1,6-hexamethylene diisocyanate and/or isophorone diisocyanateincluding isocyanurate and biuret derivatives thereof withhydroxyl-functional allyl ethers, such as the monoallyl ether of1,4-butane diol and the diallylether of trimethylol propane can be used.

Isocyanate functionality may be incorporated into a coreactive componentin a number of ways. The polyurethane (meth)acrylate or the polyurethane(meth)allyl compound may be prepared in a manner such that the reactionproduct contains unreacted isocyanate groups. For example, theabove-mentioned reaction product of 1,6-hexamethylene diisocyanateand/or isophorone diisocyanate with hydroxyethyl (meth)acrylate and/orhydroxypropyl (meth)acrylate are reacted in an NCO/OH equivalent ratioof greater than 1. Alternately, such reaction products may be preparedsuch that they are isocyanate free, i.e., NCO/OH equivalent ratio equalto or less than 1, and a separate isocyanate compound such as apolyisocyanate may be included in the coreactive component.

A polythiol coreactive component refers to polyfunctional compoundscontaining two or more thiol-functional groups (—SH). Suitablepolythiol-functional compounds include polythiols having at least twothiol groups including monomers and prepolymers. A polythiol may haveether linkages (—O—), thioether linkages (—S—), including polysulfidelinkages (—S_(x)—), where x is at least 2, such as from 2 to 4, andcombinations of such linkages.

Examples of suitable polythiols include compounds of the formulaR¹—(SH)_(n), where R¹ is a polyvalent organic moiety and n is an integerof at least 2, such as from 2 to 6.

Examples of suitable polythiols include esters of thiol-containing acidsformed by reacting a thiol-containing acid of formula HS—R²—COOH whereR² is an organic moiety with a polyhydroxyl compounds of the structureR³—(OH)_(n) where R³ is an organic moiety and n is at least 2, such asfrom 2 to 6. These components may be reacted under suitable conditionsto give polythiols having the general structure R³—(OC(O)—R²—SH)_(n)wherein R², R³ and n are as defined above.

Examples of thiol-containing acids include thioglycolic acid(HS—CH₂COOH), α-mercaptopropionic acid (HS—CH(CH₃)—COOH) andβ-mercaptopropionic acid (HS—CH₂CH₂COCH) with polyhydroxy compounds suchas glycols, triols, tetraols, pentaols, hexaols, and combinations of anyof the foregoing. Other suitable polythiols include ethylene glycolbis(thioglycolate), ethylene glycol bis(β-mercaptopropionate),trimethylolpropane tris(thioglycolate), trimethylolpropanetris(β-mercaptopropionate), pentaerythritol tetrakis(thioglycolate) andpentaerythritol tetrakis(β-mercaptopropionate), and combinations of anyof the foregoing.

Certain thermosetting compositions provided by the present disclosuremay employ Michael addition reactive components. The reactive componentsmay include primary amine-functional components and acrylate, maleic, orfumaric-functional components. Compounds that are useful primaryamine-functional components include polyoxyalkyleneamines containing twoor more primary amine groups attached to a backbone, derived, forexample, from propylene oxide, ethylene oxide, or a mixture thereof.Examples of such amines include those available under the designationJeffamine™ from Huntsman Corporation. Such amines can have a molecularweight ranging from 200 Daltons to 7500 Daltons, such as, for example,Jeffamine™ D-230, D-400, D-2000, T-403, and T-5000. Compounds useful asacrylate functional components include the acrylate functionalcomponents listed previously as embodiments of (poly)methacrylate.Compounds useful as maleic or fumaric components include polyestersprepared from maleic anhydride, maleic acid, fumaric acid, or theircorresponding C₁₋₆ alkyl esters.

A Michael acceptor group refers to an activated alkenyl group such as analkenyl group proximate to an electron-withdrawing group such as aketone, nitro, halo, nitrile, carbonyl, or nitro group. Examples ofMichael acceptor groups include vinyl ketone, vinyl sulfone, quinone,enamine, ketimine, aldimine, oxazolidine, acrylate, acrylate esters,acrylonitrile, acrylamide, maleimide, alkylmethacrylates, vinylphosphonates, and vinyl pyridines.

Suitable examples of catalysts for Michael addition chemistries includetributylphosphine, triisobutylphosphine, tri-tertiary-butylphosphine,trioctyl phosphine, tris(2,4,4-trimethylpentyl)phosphine,tricyclopentylphosphine, tricyclohexalphosphine, tri-n-octylphosphine,tri-n-dodecylphosphine, triphenyl phosphine, and dimethyl phenylphosphine.

Thermosetting compositions used in producing three-dimensional objectscan include various additives such as rheology modifiers (e.g., silicaor other fillers), flow control agents, plasticizers, stabilizers,wetting agents, dispersing auxiliaries, deformers, and adhesionpromoters. In addition, three-dimensional printing of a thermosettingcomposition can include deposition of a thermosetting composition withina mold to provide temporary structural integrity to the object duringthe printing process.

Because the thermosetting compositions can have a low viscosity comparedto thermoplastic compositions it is possible to use high fillerconcentrations. The high filler concentrations can be used to modify theproperties of the finished object such as the mechanical, thermal,and/or electrical properties of the finished object. Thus, the use ofhigh filler concentrations facilitated by the use of three-dimensionalthermosetting compositions can greatly expand the design possibilitiesof three-dimensional printing. Furthermore, thermosetting compositionscan be provided having superior solvent and chemical resistance.

Examples of suitable fillers include fumed silica such as Cabosil® TS720available from Cabot Corporation and precipitated silica such asLo-Vel®™ or Hi Sil® silicas available from PPG Industries. A curablecomposition provided by the present disclosure can comprise, forexample, from 1 wt % to 40 wt % filler, from 1 wt % to 30 wt % filler,from 1 wt % to 25 wt % filler, from 5 wt % to 25 wt % filler, or from 10wt % to 20 wt % filler, where wt % is based on the total weight of thecurable composition. A filler may be included in the A component of atwo-part system, may be included in the B part of a two-componentsystem, or a filler may be included in both the A part and the B part.

A filler can be a low density filler characterized by, for example, aspecific gravity less than 0.7, less than 0.3, or less than 0.1. Use ofa low density filler can provide a three-dimensional printed objecthaving a low specific gravity, such as from 0.8 to 1, or from 0.7 to0.9.

A filler can be an electrically-conductive filler and can be used toimpart electrically conductivity and/or EMI/RFI shielding effectivenessto a three-dimensional printed object. For example, an electricallyconductive printed object can be characterized by a sheet resistanceless than 0.5 Ω/cm² or less 0.15 Ω/cm². For example, an electricallyconductive printed object can provide effective EMI/RFI over a frequencyrange from 1 MHz to 18 GHz, or a subrange between 1 MHz to 18 GHz.

Suitable fillers also include magnetic fillers and opaque fillers.

A coreactive composition can also include a reactive rheologicalmodifier such as a polyethylene, a polyethylene or a propylene/ethylenecopolymer. Examples of suitable propylene/ethylene copolymers includePetrolite® 5000 (Baker Hughes)

A coreactive composition can comprise a low molecular weight monomericpolyamine such as a polyamine having a molecular weight from 200 Daltonsto 500 Daltons. Suitable monomeric polyamine include aliphaticpolyamines, secondary aliphatic polyamines, and combinations thereof.

The polyamine component of a coreactive composition can comprise asecondary aliphatic diamine and a propylene/ethylene copolymer.

The polyisocyanate component can comprise, for example, from 80 wt % to100 wt % of a polyisocyanate prepolymer, from 85 wt % to 95 wt %, orfrom 80 wt % to 90 wt %, wherein wt % is based on the total weight ofthe polyisocyanate component.

The polyamine component can comprise, for example, from 10 wt % to 30 wt% of a monomeric polyamine having a molecular weight from 200 Daltons to500 Daltons; from 40 wt % to 90 wt % of a polyamine prepolymer having amolecular weight from 3,000 Daltons to 7,000 Daltons; and from 1 wt % to20 wt % of a reactive rheological modifier, wherein wt % is based on thetotal weight of the polyamine component. The polyamine component cancomprise, for example, from 15 wt % to 25 wt % of a monomeric polyaminehaving a molecular weight from 200 Daltons to 500 Daltons; from 50 wt %to 80 wt % of a polyamine prepolymer having a molecular weight from3,000 Daltons to 7,000 Daltons; and from 5 wt % to 15 wt % of a reactiverheological modifier, wherein wt % is based on the total weight of thepolyamine component.

The polyisocyanate prepolymer can comprise an isophoronediisocyanate-terminated polytetramethylene prepolymer; and the polyamineprepolymer can comprise a polyetheramine prepolymer.

The polyamine component can comprise from 0.1 wt % to 20 wt % of afiller, where wt % is based on the total weight of the polyaminecomponent. The polyamine component can comprise from 0.1 wt % to 20 wt %of hydrophilic fumed silica, where wt % is based on the total weight ofthe polyamine component.

The polyisocyanate component and/or the polyamine component can becombined and extruded at room temperature. The polyisocyanate componentand/or the polyamine component can be heated prior to combination in thestatic and/or dynamic mixer. The static and/or dynamic mixer can be atroom temperature or can be heated. Prior to mixing, the polyisocyanatecomponent and/or the polyamine component can be heated to facilitatemixing of the various components. In some cases, sufficient heat can begenerated during pumping such as progressive cavity pumping, to reducethe viscosity of the polyisocyanate component and/or the polyaminecomponent to facilitate mixing of the various components.

Additively printed objects can be fabricated using the compositionsprovided by the present disclosure. An additively printed object can befabricated by deposited successive layers of a compositions comprisingcoreactive components. The compositions can be deposited, for example,using extrusion or using inkjet printing techniques.

Extrusion of coreactive components is well known. The coreactivecomponents can be mixed in a barrel head pushed under pressure through asuitably shaped nozzle. The extruded composition or extrusion can becharacterized by a cross-sectional profile. The cross-sectional profilecan be characterized by a constant ratio of the coreactive components orby a variable ratio of the coreactive components, where the ratio canrefer to the mole % ratio of the coreactive components, by theequivalents ratio of the functional groups, the wt % ratio of thereactive components, or other useful ratio. An inhomogeneous compositionacross the cross-sectional profile of an extrusion can be useful toimpart different properties to different parts of the profile. Forexample, it may be useful to impart solvent resistance or electricallyconductive properties to the outer portion of a profile. To facilitateadhesion between adjacent or adjoining layers such as underlying oroverlying layers, it may be useful to include an excess of one or moreof the coreactive functional groups. For example, a top surface or aportion of a top surface of a layer may have an excess of a firstcoreactive functional group, and a bottom surface or a portion of abottom surface of an overlying layer may have an excess of a secondcoreactive functional group, where the first and second coreactivefunctional groups are reactive with each other. In this way, formationof covalent bonding between the adjoining layers is facilitated and thephysical integrity of a finished three-dimensional printed object can beincreased.

The rate of the curing reaction between the coreactive components canalso be controlled such that the reaction is not complete when asubsequent layer is deposited on an underlying layer. In this way,coreactive components of an overlying layer can react with thecoreactive components of an underlying layer to increase the strengthbetween layers. Coreactive thermoset materials with a high degree ofcrosslinking can also be used to provide high solvent and chemicalresistance to the finished part.

The ability of an extruded curable composition to maintain structuralintegrity and support an overlying layer of the composition wasquantified by correlating the shear storage modulus G′, the shear lossmodulus G″, the tan δ (G″/G′), the complex viscosity [η*|, and theviscosity, of the curable composition with the desired properties.Desired properties, also referred to as build criteria, include theability to be deposited, the ability to maintain the shape of adeposited layer, the ability to support one or more overlying layers,and the ability to adhere or coreact with an adjacent layer. Desiredproperties also include parameters that impact the printability of acoreactive composition including the ability to extrude the coreactivecomposition from a dispensing apparatus at reasonable pressures andbefore the coreactive composition reaches a sufficiently high viscositythat the coreactive composition can no longer be dispensed.

The viscoelasticity of a curable composition can be determined using arotational rheometer to measure the shear storage modulus G′ and theshear loss modulus G″. For purposes of the present disclosure, valuesfor the shear storage modulus G′ and the shear loss modulus G″ aremeasured using an Anton Paar MCR 301 or 302 rheometer with a gap set to1 mm, with a 25 mm-diameter parallel plate spindle, and an oscillationfrequency of 1 Hz and amplitude of 0.3%. The tests are performed withthe temperature of the rheometer plate set to be 25° C.

Other material properties that can but adjusted to establish propertiessuitable for coreactive additive manufacturing include, for example, theuse of aromatic polyamines or aliphatic polyamines, the amount andproportion of hard and soft segments in the prepolymer backbone, themolecular weight and functionality of the prepolymer, the presence ofnon-reactive pendent groups, the presence of pendent hydroxyl groups,the glass transition temperature of the prepolymer, the reactivity ofthe isocyanate and amine groups, the amount and types of fillers used,the isocyanate to amine mix ration, the steric hindrance of thereactants, and a combination of any of the foregoing.

Three-dimensional objects printed according to methods provided by thepresent disclosure provide benefits over previous additivelymanufactured objects in both the process for producing the object and inthe properties of final object. For example, the deposition methods maynot require any use of added heat, therefore avoiding the creation ofstress buildup in the finished object during cooling as can occur withthree-dimensional printing of thermoplastic materials. The coreactivecompositions provided by the present disclosure can have sufficientlylow viscosity that the compositions may be pumped and printed quicklyand accurately. By using coreactive compositions that react fast andremain in place following deposition, improved control over the shapeand dimensions of a printed object may be realized. In addition, thecoreactive compositions provided by the present disclosure may includematerials that provide additional properties to the object such asmagnetic or conductive including electrical and/or thermally conductive,properties, and strength. Strengthening components include, for example,carbon fiber, glass fiber, and graphene. Colorants such as pigments ordyes can also be included in a printing composition. For coreactivecompositions that crosslink quickly, strength in the printed objectallows for rapid addition of further layers on top of the previouslyprinted portion of the object. Another benefit of the disclosedmaterials and methods is strength as provided in the “z direction” ofthe printed object, where the x and y direction are the general planesof the building of the three-dimensional object. Traditionalthree-dimensional printing provides minimal adhesion between layers ofthe printed object, particularly when thermoplastic materials are used.By providing material that forms covalent crosslinks between successivelayers, the final printed object can have increased strength in the zdirection.

Because the reaction product of coreactive materials can be adhesive theuse of a low surface energy build surface may be appropriate. Lowsurface energy build surfaces include, for example, polyolefins andfluoropolymers. Alternatively, a build surface may be coated with a moldrelease agent such as those used in polyurethane injection molding.

The use of low viscosity coreactive or thermoset compositions canfacilitate deposition at room temperature thereby avoiding the hightemperature print heads characteristic of thermoplasticthree-dimensional printing apparatus. The use of thermosetting materialscan facilitate the use of simple and light weight print heads that canbe moved rapidly and precisely and can further simplify the variousdrive mechanisms.

Depending in part on control of the rheology profile and cure rate ofthe thermosetting compositions, it is possible to rapidly build partswith high structural integrity. The structural strength between adjacentlayers can also facilitate the ability to construct shapes that overhangan underlying layer.

The at least two coreactive components can be deposited from a singlenozzle. In such cases the coreactive components can be mixed anddeposited before the curing reaction significantly proceeds, or thecoreactive components may have, for example, a sufficiently slow curingrate that they remain in liquid form following mixing. The slowlyreacting components can be deposited and a catalyst can then bedeposited from a separate nozzle to initiate the curing reaction betweenthe two coreactive components. Rather than be deposited as largedroplets, the coreactive components can be deposited as a spray.Deposition in the form of a spray can facilitate the ability of the twocoreactive components to mix prior to deposition. Because reactivethermoset compositions can have low viscosities, compared tothermoplastic compositions, deposition using sprays can be facilitated.

ASPECTS OF THE INVENTION

Aspect 1. A method of reactive additive manufacturing, comprising:providing a first component comprising a first prepolymer into a firstpump; providing a second component comprising a second prepolymer into asecond pump, wherein the second prepolymer is reactive with the firstprepolymer; pumping the first component from the first pump, and thesecond component from the second pump through a mixer to provide areactive compositions; and depositing the reactive composition through anozzle connected to the mixer.

Aspect 2. The method of aspect 1, wherein the first component comprisesa polyisocyanate prepolymer; and the second component comprises apolyamine prepolymer.

Aspect 3. The method of any one of aspects 1 to 2, wherein each of thefirst pump and the second pump independently comprise a syringe pump, aperistaltic pump, or a progressive cavity pump.

Aspect 4 The method of any one of aspects 1 to 3, wherein each of thefirst pump and the second pump comprise a progressive cavity pump.

Aspect 5. The method of any one of aspects 1 to 4, wherein the mixercomprises a static mixer, a dynamic mixer, or a combination thereof.

Aspect 6. The method of any one of aspects 1 to 5, wherein the mixercomprises a static mixer.

Aspect 7. A reactive additive manufacturing composition, comprising: afirst component comprising a polyisocyanate prepolymer and a firstviscosity; and a second component comprising a polyamine prepolymer anda second viscosity, wherein the first viscosity is within ±20% of thesecond viscosity, wherein viscosity is measured using an Anton Paar MCR301 or 302 rheometer with a 25 mm-diameter parallel plate spindle, anoscillation frequency of 1 Hz and amplitude of 0.3%, and with arheometer plate temperature of 25° C.

Aspect 8. The composition of aspect 7, wherein the first viscosity iswithin ±10% of the second viscosity.

Aspect 9. The composition of any one of aspects 7 to 8, wherein thefirst component, the second component, or both the first component andthe second component comprise from 0.1 wt % to 30 wt % of a filler,wherein wt % is based on the total weight of the first component, thesecond component, or both the first and second components, respectively.

Aspect 10. The composition of any one of aspects 7 to 9, wherein thefiller comprises an inorganic filler, an organic filler, or acombination thereof.

Aspect 11. The composition of any one of aspects 7 to 10, wherein, thepolyisocyanate prepolymer comprises a difunctional polyisocyanateprepolymer; and the polyamine prepolymer comprises a difunctionalpolyamine prepolymer.

Aspect 12. The composition of any one of aspects 7 to 12, wherein thepolyisocyanate prepolymer comprises an isocyanate-terminatedpolytetramethylene prepolymer.

Aspect 13. The composition of any one of aspects 7 to 13, wherein thepolyisocyanate prepolymer comprises an isophorone-terminatedpolytetramethylene prepolymer.

Aspect 14. The composition of any one of aspects 7 to 14, wherein thepolyamine prepolymer comprises a trifunctional polyetheramine.

Aspect 15. The composition of any one of aspects 7 to 15, wherein thepolyamine prepolymer comprising a difunctional polyamine, atrifunctional polyamine, or a combination thereof.

Aspect 16. The composition of any one of aspects 7 to 16, wherein thesecond component comprises a monomeric diamine and a rheology modifier.

Aspect 17. The composition of any one of aspects 7 to 17, wherein thesecond component comprises a secondary aliphatic diamine and apolyethylene/polypropylene copolymer.

Aspect 18. The composition of any one of aspects 7 to 18, wherein, thefirst component comprises from 80 wt % to 100 wt % of the polyisocyanateprepolymer, wherein wt % is based on the total weight of the firstcomponent; and the second component comprises: from 10 wt % to 30 wt %of a monomeric polyamine having a molecular weight within a range from200 Daltons to 500 Daltons; from 40 wt % to 90 wt % of a polyamineprepolymer having a molecular weight within a range from 3,000 Daltonsto 7,000 Daltons; and from 1 wt % to 20 wt % of a rheology modifier,wherein wt % is based on the total weight of the second component.

Aspect 19. The composition of aspect 18, wherein, the polyisocyanateprepolymer comprises an isophorone diisocyanate-terminatedpolytetramethylene prepolymer; and the polyamine prepolymer comprises apolyetheramine prepolymer.

Aspect 20. The composition of aspect 18, wherein, the polyisocyanateprepolymer comprises an isophorone diisocyanate-terminatedpolyetheramine prepolymer, such as an isophorone diisocyanate-terminatedpolyoxypropylenediamine prepolymer; and the polyamine prepolymercomprises a polyetheramine prepolymer.

Aspect 21. The composition of aspect 18, wherein, the polyisocyanateprepolymer comprises an isophorone diisocyanate-terminatedpolyoxypropylenediamine prepolymer; and the polyamine prepolymercomprises a polyetheramine prepolymer.

Aspect 22. The composition of any one of aspects 18 to 21, wherein, themonomeric amine comprises a secondary aliphatic diamine; and therheology modifier comprises a propylene/ethylene copolymer.

Aspect 23. The composition of any one of aspects 18 to 22, wherein thesecond component comprises from 0.1 wt % to 20 wt % of a filler, whereinwt % is based on the total weight of the second component.

Aspect 24. The composition of any one of aspects 18 to 23, wherein thesecond component comprises from 0.1 wt % to 20 wt % of hydrophilic fumedsilica wherein wt % is based on the total weight of the secondcomponent.

Aspect 25. The composition of any one of aspects 7 to 24, wherein thecomposition has an initial G″/G′ ratio, immediately after mixing thefirst and second component, of greater than 2, wherein the shear storagemodulus G′ and the shear loss modulus G″ are measured using a rheometerwith a gap from 1 mm to 2 mm, with a 25 mm-diameter parallel platespindle, an oscillation frequency of 1 Hz and amplitude of 0.3%, andwith a rheometer plate temperature of 25° C.

Aspect 26. The composition of any one of aspects 7 to 25, wherein thecomposition has a G″/G′ ratio at 7 minutes after mixing the first andsecond component of greater than 1, wherein the shear storage modulus G′and the shear loss modulus G″ are measured using a rheometer with a gapfrom 1 mm to 2 mm, with a 25 mm-diameter parallel plate spindle, anoscillation frequency of 1 Hz and amplitude of 0.3%, and with arheometer plate temperature of 25° C.

Aspect 27. The composition of any one of aspects 7 to 26, wherein thecomposition is characterized by a tack free time of greater than 3minutes.

Aspect 28. An object formed using the composition of any one of aspects7 to 27.

Aspect 29. The object of aspect 28, wherein the object comprises aplurality of layers, wherein adjacent layers forming the object arecovalently bonded.

Aspect 30. A method of additive manufacturing, comprising extruding thecomposition of any one of aspects 7 to 27 using a two componentprogressive cavity pump.

Aspect 31. The method of aspect 30, wherein the method comprisesextruding each of the first component and the second component into amixer.

Aspect 32. The method of any one of aspects 30 to 31, wherein the methodcomprises extruding each of the first component and the second componentinto a mixer having an exit orifice diameter from 0.6 mm to 2.5 mm, anda length from 30 mm to 150 mm.

Aspect 33. The method of any one of aspects 30 to 32, wherein the methodcomprises extruding each of the first component and the second componentinto a mixer, wherein the composition has a residence time in the mixerwithin a range from 0.25 seconds to 5 seconds.

It should be understood that, where not mutually exclusive, the variousfeatures of the embodiments of the present disclosure described, shownand/or claimed herein may be used in combination with each other. Inaddition, the following Examples are presented to demonstrate thegeneral principles of the methods and compositions provided by thepresent disclosure. All amounts listed are described in parts by weight,unless otherwise indicated. The invention should not be considered aslimited to the specific Examples presented.

EXAMPLES Example 1 Rheology Characterization

The rheology of three-dimensional printing formulations was determinedusing an Anton Paar 301 or 302 rheometer. Two-component (a polyaminecomponent and; a polyisocyanate component) samples were dispensed usinga ViscoTec ecoDUO 450 precision dosing system fitted with an in-linestatic mixer having an orifice diameter of 0.9 mm, a static mixinglength of 16 turns, and a dispensing length of 2.54 cm, and thenimmediately deposited onto the rheometer to fill the sample gap (1 mL to2 mL). A disposable sample plate (Anton Paar, Cat. No. 4847) was placedon the rheometer and used as the bottom plate in the measurements. Adisposable parallel plate spindle with a diameter of 25 mm (PP25) wasused for the measurements. The spindle was brought toward the sampleimmediately after loading, with the gap set at 1 mm. An oscillationmeasurement (frequency 1 Hz, amplitude 0.3%) was then applied.Rheological parameters (G′, G″, tan δ, |η*|) were recorded over time.The tests were performed under ambient condition with the temperature ofthe rheometer plate set to be 25° C. The results are shown in Table 1.

The polyamine component contained 66 wt % Jeffamine® T5000(polyoxyalkylene primary amine (glycerol tris[poly(propylene glycol),amine terminated] ether) of approximately 5,000 MW, available fromHuntsman Corp.), 19 wt % Clearlink® 1000 (aliphatic secondary amine,available from Dorf-Ketal Chemicals, LLC.), and 10 wt % Petrolite® 5000(propylene/ethylene copolymer, available from Baker Hughes), where wt %is based on the total weight of the polyamine component The polyaminecomponent further contained either 5 wt % or 8.5 wt % of Cabosil® TS-720(fumed silica available from Cabot Corp.) filler.

The isocyanate component contained either the reaction product of 77 wt% Jeffamine® D-2000 (polyoxypropylenediamine) and 23 wt % isophoronediisocyanate; or the reaction product of 73 wt % Polymeg® 2000(polytetramethylene ether glycol) and 27 wt % isophorone diisocyanate,where wt % is based on the total weight of the composition.

TABLE 1 Dynamic modulus parameters for the polyurea formulations. Fillerwt % Isocyanate Cabosil ® G′ G″ Formulation Component TS-720 t = 0 t = 0G″/G′ δ A1 Polymeg ® 5 762 2050 2.69 69.61 2000/IPDI A2 Polymeg ® 5 35008500 2.43 67.62 2000/IPDI B Polymeg ® 8.5 654 3110 4.76 78.12 2000/IPDIC1 Jeffamine ® 5 102 342 3.35 73.39 D2000/IPDI C2 Jeffamine ® 5 120000120000 1.00 45.00 D2000/IPDI D Jeffamine ® 8.5 8330 9390 1.13 48.42D2000/IPDI

Formulations A1, A2, B and D could be successfully printed.

Formulations C1 and C2 cured too fast and clogged the dispensing nozzle.The large variability in the G′ and G″ values for C1 and C2 are anartifact of the rapid curing. Compositions C1 and C2 are the same,however, because the C1 and C2 compositions cure very fast it isdifficult to establish t=0, which results in a large apparentvariability in the initial G′ and G″ values. Increasing the fillercontent from 5 wt % to 8.5 wt % slowed the curing rate so that theJeffamine® D-2000/IPDI composition could be successfully printed.

Example 2 Tack-Free Times

A hand pump was used to extrude the polyurea formulations of Example 1.The Jeffamine® D2000 formulations (C1, C2, and D) were considerably moredifficult to pump than the Polymeg® 2000 formulations (A1, A2, and B),and gelled in the nozzle quickly. The tack-free time was determinedusing a drawdown method at a 1-mil thickness. For the drawdown method1-mil thick uniform film was applied the length of an 8½-inch×11-inch(21.6-inch×27.94-inch) sheet of polyethylene using a square frame 8 pathapplicator #34 (Precision Gage & Tool Co.). About 10 mL of the polyureaformulation was extruded within the boundaries of the applicator, whichis coated with Chem Trend MR-515 release agent to prevent curing on theapplicator. When the film is drawn down, a cotton ball is gently pressedagainst the film and removed (a dab). The quantity of adhered cotton isvisually monitored as the cotton ball is repeatedly dabbed against thefilm without dabbing the same area more than once. As the quantity ofadhere cotton decreases, the frequency of dabbing increases, such thatthe dabbing interval is no longer than 5 sec when there is almost nocotton adhered to the film. The time recorded from when the film isdrawn down until no cotton adheres to the film is the tack-free time.The results are shown in Table 2.

TABLE 2 Tack-free time of coreactive formulations. Polyisocyanate Filler(wt %) Tack-Free Sample Prepolymer Cabosil ® TS-720 Time (min:sec) C1Jeffamine ® D2000/IPDI 5 wt % 3:26 D Jeffamine ® D2000/IPDI 8.5 wt %2:48 A1 Polymeg ® 2000/IPDI 5 wt % 4:47 B1 Polymeg ® 2000/IPDI 8.5 wt %5:39 B2 Polymeg ® 2000/IPDI 8.5 wt % 5:36

Whereas particular embodiments of this invention have been describedabove for purposes of illustration, it will be evident to those skilledin the art that numerous variations of the details of the presentinvention may be made without departing from the invention as defined inthe appended claims.

What is claimed is:
 1. A reactive additive manufacturing composition,comprising: a first component comprising a polyisocyanate prepolymer anda first viscosity; and a second component comprising a polyamineprepolymer and a second viscosity, wherein the first viscosity is within±20% of the second viscosity, wherein viscosity is measured using anAnton Paar MCR 301 or 302 rheometer with a 25 mm-diameter parallel platespindle, an oscillation frequency of 1 Hz and amplitude of 0.3%, andwith a rheometer plate temperature of 25° C.; and wherein thecomposition is characterized by a tack free time of greater than 3minutes.
 2. The composition of claim 1, wherein the first viscosity iswithin ±10% of the second viscosity.
 3. The composition of claim 1,wherein the first component, the second component, or both the firstcomponent and the second component comprise from 0.1 wt % to 30 wt % ofa filler, wherein wt % is based on the total weight of the firstcomponent, the second component, or both the first and secondcomponents, respectively.
 4. The composition of claim 3, wherein thefiller comprises an inorganic filler, an organic filler, or acombination thereof.
 5. The composition of claim 1, wherein, thepolyisocyanate prepolymer comprises a difunctional polyisocyanateprepolymer; and the polyamine prepolymer comprises a difunctionalpolyamine prepolymer.
 6. The composition of claim 1, wherein thepolyisocyanate prepolymer comprises an isocyanate-terminatedpolytetramethylene prepolymer.
 7. The composition of claim 1, whereinthe polyisocyanate prepolymer comprises an isophorone-terminatedpolytetramethylene prepolymer.
 8. The composition of claim 1, whereinthe polyamine prepolymer comprises a trifunctional polyetheramine. 9.The composition of claim 1, wherein the polyamine prepolymer comprises adifunctional polyamine, a trifunctional polyamine, or a combinationthereof.
 10. The composition of claim 1, wherein the second componentcomprises a monomeric diamine and a rheology modifier.
 11. Thecomposition of claim 1, wherein the second component comprises asecondary aliphatic diamine and a polyethylene/polypropylene copolymer.12. The composition of claim 1, wherein, the first component comprisesfrom 80 wt % to 100 wt % of the polyisocyanate prepolymer, wherein wt %is based on the total weight of the first component; and the secondcomponent comprises: from 10 wt % to 30 wt % of a monomeric polyaminehaving a molecular weight within a range from 200 Daltons to 500Daltons; from 40 wt % to 90 wt % of a polyamine prepolymer having amolecular weight within a range from 3,000 Daltons to 7,000 Daltons; andfrom 1 wt % to 20 wt % of a rheology modifier, wherein wt % is based onthe total weight of the second component.
 13. The composition of claim12, wherein, the polyisocyanate prepolymer comprises an isophoronediisocyanate-terminated polytetramethylene prepolymer; and the polyamineprepolymer comprises a polyetheramine prepolymer.
 14. The composition ofclaim 12, wherein, the polyisocyanate prepolymer comprises an isophoronediisocyanate-terminated polyetheramine prepolymer; and the polyamineprepolymer comprises a polyetheramine prepolymer.
 15. The composition ofclaim 12, wherein, the polyisocyanate prepolymer comprises an isophoronediisocyanate-terminated polyoxypropylenediamine prepolymer; and thepolyamine prepolymer comprises a polyetheramine prepolymer.
 16. Thecomposition of claim 12, wherein, the monomeric amine comprises asecondary aliphatic diamine; and the rheology modifier comprises apropylene/ethylene copolymer.
 17. The composition of claim 12, whereinthe second component comprises from 0.1 wt % to 20 wt % of a filler,wherein wt % is based on the total weight of the second component. 18.The composition of claim 12, wherein the second component comprises from0.1 wt % to 20 wt % of hydrophilic fumed silica wherein wt % is based onthe total weight of the second component.
 19. The composition of claim1, wherein the composition has an initial G″/G′ ratio, immediately aftermixing the first and second component, of greater than 2, wherein theshear storage modulus G′ and the shear loss modulus G″ are measuredusing a rheometer with a gap from 1 mm to 2 mm, with a 25 mm-diameterparallel plate spindle, an oscillation frequency of 1 Hz and amplitudeof 0.3%, and with a rheometer plate temperature of 25° C.
 20. Thecomposition of claim 1, wherein the composition has a G″/G′ ratio at 7minutes after mixing the first and second component of greater than 1,wherein the shear storage modulus G′ and the shear loss modulus G″ aremeasured using a rheometer with a gap from 1 mm to 2 mm, with a 25mm-diameter parallel plate spindle, an oscillation frequency of 1 Hz andamplitude of 0.3%, and with a rheometer plate temperature of 25° C. 21.An object formed using the composition of claim
 1. 22. The object ofclaim 21, wherein the object comprises a plurality of layers, whereinadjacent layers forming the object are covalently bonded.
 23. A methodof additive manufacturing, comprising extruding the reactive additivemanufacturing composition of claim 1 using a two component progressivecavity pump.
 24. The method of claim 23, wherein the method comprisesextruding each of the first component and the second component into amixer.
 25. The method of claim 23, wherein the method comprisesextruding each of the first component and the second component into amixer having an exit orifice diameter from 0.6 mm to 2.5 mm, and alength from 30 mm to 150 mm.
 26. The method of claim 23, wherein themethod comprises extruding each of the first component and the secondcomponent into a mixer, wherein the composition has a residence time inthe mixer within a range from 0.25 seconds to 5 seconds.
 27. Thecomposition of claim 1, wherein the composition comprises a rheologymodifier.
 28. The composition of claim 27, wherein the rheology modifiercomprises a filler, a polymer, or a combination thereof.
 29. Thecomposition of claim 27, wherein the rheology modifier comprises areactive rheology modifier.
 30. The composition of claim 27, wherein therheology modifier comprises polyethylene, a polyethylene/ethylenecopolymer, a polypropylene/ethylene copolymer, or a combination of anyof the foregoing.
 31. The composition of claim 1, wherein thecomposition comprises low-density filler, electrically conductivefiller, magnetic filler, opaque filler, an inorganic filler, an organicfiller, or a combination of any of the foregoing.
 32. The composition ofclaim 1, wherein the composition comprises from 1 wt % to 40 wt % of afiller, wherein wt % is based on the total weight of the composition.33. The composition of claim 1, wherein the polyisocyanate prepolymerand the polyamine prepolymer independently have a molecular weight from400 Daltons to 8,000 Daltons.
 34. The composition of claim 1, whereinthe first component comprises a polyisocyanate monomer and/or the secondcomponent comprises a polyamine monomer.
 35. A method of additivemanufacturing comprising extruding the reactive additive manufacturingcomposition of claim
 1. 36. A method of reactive additive manufacturingusing the composition of claim 1, comprising: providing the firstcomponent into a first pump; providing the second component into asecond pump, wherein the second prepolymer is reactive with the firstprepolymer; pumping the first component from the first pump, and thesecond component from the second pump through a mixer to provide areactive composition; and depositing the reactive composition through anozzle connected to the mixer.
 37. The method of claim 36, wherein eachof the first pump and the second pump independently comprise a syringepump, a peristaltic pump, or a progressive cavity pump.
 38. The methodof claim 36, wherein each of the first pump and the second pumpcomprises a progressive cavity pump.
 39. The method of claim 36, whereinthe mixer comprises a static mixer, a dynamic mixer, or a combinationthereof.
 40. The method of claim 36, wherein the mixer comprises astatic mixer.